Defect Map Layout for Nesting and Shear Cutting of Plates
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Solution Overview
Problem
The high scrap rate in plate processing is caused by defects such as folds and holes in the plates, which are not adequately addressed in existing technologies, leading to the production of defective and unqualified products.
Innovation Solution
A preprocessing method that involves creating an electronic defect map based on defect and dimension information to partition regions suitable for nesting and shear cutting, followed by partitioning the plate into small plates, and a layout method that sets decision variables and constraints to optimize the processing of these small plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional nesting and shear cutting is performed without considering plate defects, then processing efficiency is maintained, but the scrap rate increases due to production of defective products
Solution Approach 1:
The patent creates an electronic defect map before nesting and shear cutting operations to identify and mark defective regions on the plate. This preliminary action allows the nesting algorithm to avoid placing parts on defective areas, thereby preventing production of defective products and reducing scrap rate without compromising processing efficiency
Solution Approach 2:
The patent applies different processing strategies to different regions of the plate based on their quality. Defective regions are excluded from nesting, while non-defective regions are optimized for part placement. This local quality approach ensures that only suitable areas of the plate are used for production, reducing waste from defective products
2Loss of time
If the plate is partitioned into small plates without defect information, then processing can proceed quickly, but defective products are produced increasing scrap rate
Solution Approach 1:
The patent performs preliminary partitioning of the plate into small plates based on defect information before the actual nesting and cutting operations. The electronic defect map guides this partitioning process to ensure that small plates are created in a way that avoids defective regions, preventing future production of defective products while maintaining efficient processing
Solution Approach 2:
The patent segments the large plate into multiple small plates based on defect locations and nesting requirements. This segmentation allows the nesting algorithm to work on smaller, defect-free regions independently, improving both processing efficiency and product quality by ensuring each small plate can be processed without producing defective items
3Reliability
If defect information is fully integrated into the nesting and layout process, then product quality improves, but system complexity increases
Solution Approach 1:
The patent creates an electronic defect map, which is a digital copy or representation of the actual plate defects. This electronic model allows the nesting and layout algorithms to work with defect information without requiring physical inspection during processing, improving product quality while keeping the system manageable through software-based solutions
Solution Approach 2:
The patent introduces an electronic defect map as an intermediary between the physical plate defects and the nesting/layout algorithms. This intermediary translates physical defect information into a format that can be easily processed by computer algorithms, simplifying the integration of defect consideration into the processing system while maintaining high product quality
Data Source
AI summary
A nesting and shear cutting preprocessing method for a defective plate, comprising the following steps: acquiring plate information of a plate, wherein the plate information includes defect information and plate dimension information; making an electronic defect map according to the defect information and the plate dimension information, and partitioning out a region available for nesting and shear cutting; and partitioning the plate to obtain small plates according to the region available for nesting and shear cutting. A nesting and shear cutting layout method for a defective plate, a nesting and shear cutting production optimization method for a defective plate, and a system, a computing device, a storage medium therefor. The preprocessing method and the system can reduce the scrap rate of plate processing.